GEF - UNIDO - BEE PROJECT

on
“Promoting EE/RE in selected
MSME Clusters in India”

PUMPING SYSTEM

Overhead Tank

Pump – Simple Definition

Pump Pump is a machine used to lift

a fluid from a lower level to a
higher level.

Pump is a mechanical device

which raises the energy levels
of various fluids by converting
the kinetic energy imparted by
its prime movers into hydraulic
energy.
Well
 Life Cycle cost for a Pump

Maintenance Cost Initial Cost

8% 2%

Energy Cost

90%

30 kW pump
Initial cost: Rs 3,00,000/-

Operating hours: 8000/year

Power cost: Rs 5/unit

Lifetime: 15 years

Maintenance: Rs 30,000/-

Life Cycle Cost: Rs 187,50,000/-

Centrifugal Pumps

Centrifugal Pumps have a rotating element , called

impeller, through which as the liquid passes its
angular momentum changes , due to which the
pressure energy of the liquid is increased.

Fluid Outlet

Volute (housing)
Moderate pressure
(upto 6000 m WC)
Diffuser
Casing
Moderate capacity
Impeller (upto 10,000 m3/h)

Fluid
Inlet
General
Guide applications
Vanes
 Positive Displacement Pumps

Positive displacement pumps are those in which

liquid is sucked and then pushed due to the thrust
exerted on it by a moving member, which results in
lifting the liquid to the required height.

Discharge
Piston
Connecting
Crosshead rod
Discharge
Valve T

T
Suction
Valve Crankshaft
Suction

Reciprocating
High pressure - upto 10,000 m WC
Low capacity - upto 1000 m3/h
Lubrication oil pumps

Parts of Pumps

A
B J

C H

D G

A Stuffing Box E Vane I Casing wear Ring

B Packing F Casing J Impeller
C Shaft G Eye of Impeller K Discharge Nozzle
D Shaft Sleeve H Impeller
 Typical Pumping Layout

Process
Process
Sump

Energy Parameters

Capacity
or Flow

Efficiency Head or
Pressure

Efficiency of Pump

Flow (Q)
P2

P1

R
Y Pin
B
Pout = Efficiency X Pin

Flow (lps) x (h2-h1) (m) x Sp. Gr.

Pump η (%)
= 102 x Pout
Pumps Formulae
If the RPM is reduced
by say 10%,
what will happen to the

Capacity
reduces Head
by 10% reduces Power
by 19% reduces
by 27%
Capacity
N

Power Head
N3 N2

Reasons for excess power consumption

1 Wrong Selection

2 Over Design

3 Improper Layout

4 Old Improper Pumps

5 Multiple Smaller Size Pumps

6 Poor Operational Practices

Pressure Drop Across Valve

Process

Valve
Partially
open
P2 P3

Storage tank
P1

Pr. Drop Across Valve = P2 - P3

Total Pr. Rise = P2 - P1
Energy Saving Potential = [(P2-P3)/(P2-P1)]
 Various Control Techniques in Pumps

Throttle Control

H p = Hs + H v
Throttle
Hp Value

Hv
System
Hs

Bypass Control

Bypass Value

Qp = Qs + Qbp
Qbp

Qp Qs
System
Hp

Modifying Impeller Diameter

Q~D
D H ~ D2
N ~ D3

Speed Control

Speed Control
 Effect of Various Capacity Controls
Power (kW)

Case Study - Segregate high

and low head users

200m3 /h
30m ht.

Cold well 50%

300m3 /h
Gr. Flr.

500m3 /h
40m, 91.5 kW

200m3 /h
30m ht.

Cold well
300m3 /h
200m /h
3
Gr. Flr.
40m, 37.5 kW

300m3 /h
20m, 27.5 kW

Annual Savings = Rs. 4.80 Lakhs

Investment = Rs. 6.00 Lakhs
Payback period = 15 Months
 Series and Parallel Operation

Series Operation

Two Pumps in Series

Single 2
Head -h

Pump
3

System 1
Curve

Flow Rate - q

Head will become double

Flow will be same

Parallel Operation

Two Pumps in Parallel

Head -h

3
Single Pump

1 2
System Curve

Flow Rate - q

Flow will become double

Head will be same
 Symptoms indicating opportunities
for energy saving

Symptom Likely Reason Best Solutions

Throttle Trim impeller,

valve- Oversized smaller impeller,
controlled pump variable speed drive,
systems two speed drive,
lower rpm

By Pass line Trim Impeller,

(partially or Oversized smaller impeller,
completely) pump variable speed drive,
open lower rpm

Multiple
parallel
pump Pump use
system not Install
with same monitored controls
no of pumps or controlled
always
operating

Constant
pump Wrong On off
operation system controls
in batch design
environment

High
Pump Match pump
maintenance
operating capacity
cost (seals,
away from with system
bearings)
BEP requirement
 Energy Efficient Pumping System

Conventional Pumping System

(Efficiency ~ 31%)

Throttle efficiency
Coupling = 66%
efficiency
= 98%
Output
Input
Pump Pipe efficiency Power
Power
efficiency = 69% 31
100
Standard motor = 77%
efficiency = 90%

Efficiency Optimized Pumping System

(Efficiency ~ 72%)
Variable speed
Coupling Improved
drive efficiency
efficiency piping = 90%
= 95%
= 99%
Output
Input
Power
Power
71.5
100 High
High efficiency
motor = 95% efficiency Pump
= 88%

EE Opportunities in Pumping System

Operate Pumps near best efficiency point

and replace old pumps with energy efficient
pumps

Modify pumping system and pump losses

to minimize throtteling

Use variable speed drives to meet vide load

variation

Avoid cooling water recirculation in DG set,

compressor, refrigeration system etc.

Use gravity flow whenever possible

Use gravity flow whenever possible

Optimize no of stages in multi stage pumps

in case of head margin

For over designed pumps, downsize

or replace impeller or replace with correct
size pump for efficient operation
 Pump Maintenance Check List

Maintainance
Description Comments Frequency

Annualy
Monthly
Weekly
Daily
Pump use/ Turn off/sequence
Sequensing unneccessary pumps

Overall Visual Complete all overall

Inspection visual inspection to be
sure all equipments is
working and safety
systems are in place

Check Assure that all bearings

Lubrication are lubricated as per
the manufacturer’s
instruction

Check Packing Check packing for the

wear and repack as
neccessary. Consider
replacing packing with
mechanical seals

Motor/pump Aligning the pump/

Alignment motor couplings allows
for efficient torque
transfer to the pump

Check Check and secure all

Mountings the pump mountings

Check Inspect bearings and

Bearings drive belts for wear.
Adjust,repair or replace
as neccessary.

Motor Checking for the

Condition condition of the motor
through tempreture or
vibration analysis
assures long life
About Project

Promoting Energy Efficiency & Renewable

Energy in Selected MSME Clusters in India

To develop and promote a market environment for

introducing energy efficiency and enhanced use of
renewable energy technologies in process
applications in the selected energy-intensive MSME
clusters under GEF UNIDO BEE project.
The main objective of the project is to increase the
capacity building of suppliers of EE/RE product and
service providers

Desclaimer
CII has made every effort to ensure
the accuracy of information presented in this
manual. However, neither CII nor any of its
employees can be held responsible for any
financial consequences arising out of the use of
information provided herein. However in case of
any discrepancy, error etc , same may please be
brought to the notice of CII for appropriate
corrections.

Mr. Niranjan Rao Deevela

UNIDO
[Link]@[Link]
+91 9560003730

Mr. P. V. Kiran Ananth

CII
[Link]@[Link]
+91 40 44185152